Packages for and methods of packaging food products

ABSTRACT

A package for food products including a first portion, a second portion, and at least one indicator. The first portion has a first closed end, at least one first side wall surrounding the first closed end, and a first open end opposite the first closed end. The second portion has a second closed end, at least one second side wall surrounding said second closed end, and a second open end opposite the second closed end. The first portion and second portion are movably connected at their respective open ends. The at least one indicator is placed in communication with the package such that when the package is expanded to a desired inner volume the indicator is activated. The closed end of either portion may be opened when a desired inner volume of a food product is reached.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of co-pending U.S. patentapplication Ser. No. 12/704,954, filed Feb. 12, 2010, and entitledPACKAGES AND METHODS OF PACKAGING FOOD PRODUCTS, the contents of whichapplication are incorporated by reference herein in their entirety forall purposes.

FIELD OF THE INVENTION

In general, the invention relates to a packaging device for foodproducts. More particularly, the invention relates to expandablepackages for food products.

BACKGROUND OF THE INVENTION

The art of food packaging is well developed. For example, within the artof dough packaging there are multiple ways of packaging proofed andun-proofed dough. Proofing dough is know in the art to mean allowingdough containing a leavening agent to rise for the proper amount of timesuch that the dough reaches a desired volume.

U.S. Pat. No. 6,635,291, Perry, entitled Leavened Dough or BatterPackaging System discloses a package for leavened dough designed to holda desired internal equilibrium pressure.

U.S. Pat. No. 6,733,803, Vidkjaer, entitled Dough Containing, ValvedPackage discloses a package for dough that does not have to be proofedhaving a one-way venting valve to allow gas to escape from the package.

U.S. Pat. No. 1,861,124, Lorber, entitled Biscuit Package discloses apackage for uncooked biscuits having a telescoping cover which providesspace for the risen dough. Further, Lorber's design has a channel forreceiving the telescoping cover and requires separation of a number ofdough cakes with interposed circular disks which may complicateproducing such a design.

U.S. Pat. No. 6,240,839, Amato, entitled Device for Proofing Doughdiscloses a mechanical device having an electronic alarm or electronicvisual indicator assembly for signaling when the dough reaches aspecific volume.

Most of the prior art mentioned above does not provide for packaging ofun-proofed dough products. Known packages that do provide for packagingof un-proofed dough do not indicate when the dough is ready or proofed.Letting dough proof for the proper amount of time is an art. The time ittakes dough to proof is dependent upon many variables such astemperature, humidity, dough ingredients and the strain of yeast used inthe dough. Thus, the proof time of dough is often misjudged and thedough is used either prematurely or after it has proofed. Furthermore,known proofing approaches for dough generally require the consumer topurchase a separate device, apart from the dough packaging, to determinewhen the dough is ready. Such known prior art devices that indicate whendough is ready tend to be expensive and more suited for commercialoperations.

Furthermore, recent health concerns around the food packaging of popcornin microwave ready packages have created a need for an expandable foodpackage for popcorn that is chemical free, made from virgin fiberpaperboard, recyclable and compostable.

SUMMARY OF THE INVENTION

Embodiments of the invention relate to packages for food products. Morespecifically, embodiments of the invention relate to inexpensiveexpandable packages in which dough can be sold and in which dough can beproofed to the correct/desired volume by consumers.

In one embodiment of the present invention the package has two portions,a first portion and a second portion. The first portion has a firstclosed end, at least one first side wall surrounding the first closedend, and a first open end opposite the first closed end. The secondportion has a second closed end, at least one second side wallsurrounding said second closed end, and a second open end opposite thesecond closed end. The first portion and second portion are movablyconnected at their respective open ends, such that an enclosed void ofvariable volume is created between the first closed end and the secondclosed end. Additionally, at least one indicator is placed incommunication with the package such that when the package is expanded toa desired inner volume the indicator is activated. Activation of theindicator may produce, for example, a visual indication, an audioindication, an indication recognizable by touch, or any combinationthereof.

The packages of the present invention provide for an inexpensive andeasily manufacturable package for food products. Furthermore, thepackages of the present invention provide for a dough package in whichdough can be manufactured, sold, and proofed to the correct or desiredvolume without the need for separate more expensive devices.

In a further illustrative embodiment of the present invention, thepackages of the present invention provide for a use as a food packagefor popcorn allowing for the popping of corn to a desired volume withoutthe need for separate more expensive device. According to the invention,the instant food package can further be used as a serving container forthe expanded food product.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention is illustrated in the figures of the accompanying drawingswhich are meant to be exemplary and not limiting, in which likereferences are intended to refer to like or corresponding parts, and inwhich:

FIG. 1 illustrates an embodiment of an expandable package wherein theexpandable package is expanded to show an indicator;

FIG. 2 illustrates an embodiment of an expandable package wherein theexpandable package is fully collapsed;

FIG. 3 illustrates an embodiment of an expandable package wherein theexpandable package portions are separated to show the interfaceportions;

FIG. 4 illustrates an embodiment of a method of making an expandablepackage;

FIG. 5 illustrates an embodiment of a pattern for making the portions ofan expandable package;

FIG. 6 illustrates another embodiment of a pattern for making theportions of an expandable package;

FIG. 7 illustrates an embodiment of a method of packaging a food productin an expandable package;

FIG. 8 illustrates an embodiment of a pattern for making the portions ofan expandable package; and

FIG. 9 illustrates another embodiment of a pattern for making theportions of an expandable package.

DETAILED DESCRIPTION

Detailed embodiments of the present invention are disclosed herein,however, it is to be understood that the disclosed embodiments aremerely exemplary of the invention, which may be embodied in variousforms. Therefore, specific functional details disclosed herein are notto be interpreted as limiting, but merely as a basis for the claims andas a representative basis for teaching one skilled in the art tovariously employ the present invention.

In general, aspects of the invention relate to packaging, and methods ofmaking a package and packaging a food product. In one aspect, theinvention relates to an expandable package for packaging food products.Referring first to FIGS. 1-3, wherein FIG. 1 depicts an expanded packagewith a square/rectangular cross section, FIG. 2 depicts a collapsedpackage with a square/rectangular cross section, and FIG. 3 depicts apackage having a square/rectangular cross section with the packageportions separated from one another. One embodiment of the packageincludes a first portion 100, a second portion 101, and at least oneindicator 102.

The first portion 100 has a first closed end 103, at least one firstside wall 104 surrounding the first closed end 103, and a first open end105 opposite the first closed end 103. The second portion 101 has asecond closed end 106, at least one second side wall 107 surrounding thesecond closed end 106, and a second open end 108 opposite the secondclosed end 106. The first portion 100 and second portion 101 are movablyconnected at their respective open ends 105 and 108 such that anenclosed void of variable volume is created between the first closed end103 and the second closed end 106.

The at least one indicator 102 is placed in communication with thepackage such that when the package is expanded to a desired inner volumethe indicator 102 is activated. As shown in FIG. 1, activation of theindicator 102 produces a visual indication that may read “Half Proofed,”or “Fully Proofed” depending on the inner volume of the package. In afurther illustrative embodiment a singular visual indication may read“Pop Corn Done,” or may be just a simple line showing the food packageis at full volume. It is contemplated within the scope of the inventionthat the visual indicator may reflect a variety of food products invarious stages of readiness. Although, only printed words are shown inFIG. 1, it is contemplated that any number of any words, descriptions,phrases, symbols, pictures, combinations thereof, or other visualindication means may be used. It is further contemplated that activationof the indicator may produce, for example, a visual indication, an audioindication, an indication recognizable by touch, or any combinationthereof.

In other embodiments, the indicator 102 is activated when the innervolume of the package reaches a volume in the range of about 90 to 94cubic inches, and/or when the inner volume of the package reaches avolume in the range of about 108 to 112 cubic inches.

As shown in FIGS. 1-3, the package is depicted as having asquare/rectangular cross section. However, in other embodiments of thepackage any cross sectional shape may be used, for example, a crosssection that is circular, square, rectangular, octagonal, triangular,hexagonal, pentagonal, or any combination thereof.

Another embodiment of the package, as shown in FIG. 3, includes at leastone first interface portion 300 at the first open end 105 of the firstportion 100, and at least one second interface portion 301 at the secondopen end 108 of the second portion 101. These interface portions 300 and301 engage with each other when the first and second portions 100 and101 are connected and allow the package to expand and contract in volumeas the first and/or second portion(s) 100 and 101 is moved. The purposeof the interface portions 300 and 301 is to prevent the package fromexpanding to far and separating the first and second portions 100 and101 apart. As shown in FIG. 3, the interface portions are depicted astabs folded inward on the first portion 100 and outward on the secondportion 101. However, it is contemplated that any means of preventingthe two portions 100 and 101 from separating apart when the package isexpanded may be used.

Further embodiments of the package may include one or more of thefollowing features. The first portion 100 wherein the first closed end103 is capable of being opened such that the food product packed withincan be removed. As shown in FIGS. 1-3, the package is shown as expandingvertically. However, in other embodiments of the package anyconfiguration may be used, for example, the package may expandvertically, horizontally, or on an angle. Furthermore, FIGS. 1 and 2depict the package as having a second portion 101 which is smaller thatthe first portion 100 such that the second portion 101 fits within thefirst portion 100. However, in other embodiments of the package thefirst portion 100 is smaller than the second portion 101 and is placedwithin the second portion 101.

In another aspect, the invention relates to a method of making anexpandable package. Referring to FIG. 4, one embodiment of the methodfor making a package includes providing a first portion pattern 400,providing a second portion pattern 401, bending or folding the firstportion pattern 402, bending or folding the second portion pattern 403,fastening the first portion such that the first portion retains thefolded configuration 404 and fastening the second portion such that thesecond portion retains the folded configuration 404, and assembling thefirst portion and the second portion 405.

More specifically, bending or folding the first portion 402 includesfolding the first portion pattern to form a first portion having a firstclosed end, at least one first side wall surrounding the first closedend, a first open end opposite the first closed end, and at least onefirst interface portion at the first open end. Bending or folding thesecond portion 403 includes folding the second portion pattern to form asecond portion having a second closed end, at least one second side wallsurrounding the second closed end, a second open end opposite the secondclosed end, and at least one second interface portion at the second openend.

The fastening step 404 includes securing the bended or folded patternswith any adhesive material to maintain their bended or foldedconfigurations of the first and second portions. Furthermore, assemblingthe first portion and the second portion 405 includes assembling thefirst and second portions such that the first interface portion of thefirst portion engages with the second interface portion of the secondportion, and thus producing a package in which the first and secondportions are movably attached to each other at their respective openends.

Other embodiments of the method for making a package, may include one ormore of the following steps: providing sheet stock for printing onto406; printing graphics or other designs onto a sheet stock 407; and diecutting or laser cutting the patterns for the first and second portionsout of a printed or un-printed sheet stock 408.

One example of a pattern for producing the first and/or second portionsis shown in FIG. 5, wherein the dashed lines represent folds or bends.Bending/folding and fastening the pattern depicted in FIG. 5 into afirst and/or second portion includes the following, not necessarily inthe following order: fastening tab 500 to edge 501, folding the two tabs502 toward the center, folding end 503 over the two tabs 502, insertingtab 504 into the enclosure, and folding the interface tabs 505 in thedesired direction depending on which portion is being folded, asmentioned above.

Another example of a pattern for producing the first and/or secondportions is shown in FIG. 6, wherein the dashed lines represent folds orbends. Bending/folding and fastening the pattern depicted in FIG. 6 intoa first and/or second portion includes the following, not necessarily inthe following order: fastening tab 600 to edge 601, folding the two tabs602 toward the center, folding and interlocking the two end tabs 603together over the two tabs 602 and fastening, and folding the interfacetabs 604 in the desired direction depending on which portion is beingfolded, as mentioned above.

FIGS. 5 and 6 depict the pattern as producing a first and/or secondportion having a square/rectangular cross section. However, in otherembodiments of the pattern may produce a first and/or second portionhaving any cross sectional shape may be used, for example, a crosssection that is circular, square, rectangular, octagonal, triangular,hexagonal, pentagonal, or any combination thereof. Although FIGS. 5 and6 only provide two examples it is contemplated that other patterns couldbe used to create embodiments of the invention.

In another aspect, the invention relates to a method for packaging afood product. Referring to FIG. 7, one embodiment of the method ofpackaging includes providing a food product 700, providing a package701, and enclosing the food product within the package 702. Providing afood product 700 may further include providing a food product such asdough or popcorn. Enclosing the food product within the package 702 mayfurther include placing the food product inside the package and closingthe package.

Furthermore, providing a package 701 includes providing a package,having a first portion, a second portion, and at least one indicator.The first portion has a first closed end, at least one first side wallsurrounding the first closed end, and a first open end opposite thefirst closed end. The second portion has a second closed end, at leastone second side wall surrounding said second closed end, and a secondopen end opposite the second closed end. The first portion and secondportion are movably connected at their respective open ends. The atleast one indicator is placed in communication with the package suchthat when the package is expanded to a desired inner volume theindicator is activated.

A further example of a pattern for producing the first and/or secondportions according to the invention is shown in FIG. 8, wherein thedashed lines represent folds or bends. Bending/folding and fastening thepattern depicted in FIG. 8 into a first and/or second portion includesthe following, not necessarily in the following order: fastening tab 800to edge 801, folding the two tabs 802 toward the center, folding end 803over the two tabs 802, inserting tab 804 into the enclosure, and foldingthe interface tabs 805 in the desired direction depending on whichportion is being folded, as mentioned above. The folded pattern asdepicted in FIG. 8 creates a bottom portion of a food packagingaccording to the invention. According to the invention, as shown in FIG.8, this pattern has side panels 806 each having a radial depressions 807for receiving setting tabs 906 (shown in FIG. 9).

Another example of a pattern for producing the first and/or secondportions according to the invention is shown in FIG. 9, wherein thedashed lines represent folds or bends. Bending/folding and fastening thepattern depicted in FIG. 9 into a first and/or second portion includesthe following, not necessarily in the following order: fastening tab 900to edge 901, folding the two tabs 902 toward the center, folding andinterlocking the two end tabs 903 together over the two tabs 902 andfastening with the interlocking tabs 905 contained with the two end tabs903, and folding the interface tabs 904 in the desired directiondepending on which portion is being folded, as mentioned above. Thefolded pattern as depicted in FIG. 9 creates a top portion of the foodpackaging according to the invention. As shown in FIG. 9, thisillustrative pattern has setting tabs 906 that interface with the radialdepressions 807 of the bottom portion (shown in FIG. 8). The settingtabs 906 allow the top and bottom portions to remain in an expandedvolume after the expansion of a food product within the first and secondportion allowing one to use the food package according to the inventionas a serving container. The interlocking tabs 905 allow for the top endof the top portion to be opened after the expanded food product is inits ready to consume state allowing access to expanded volume of a foodproduct that is ready to consume. It is contemplated within the scope ofthe invention that the top and bottom portions described in FIGS. 8 and9 can be utilized for expandable food products such as popcorn. It isfurther contemplated within the scope of the invention that anyexpandable food product may be packaged within the top and bottomportions described in FIGS. 8 and 9.

According to the invention, FIGS. 8 and 9 provides a food package 701having a first portion, a second portion, and at least one indicator.The first portion has a first closed end, at least one first side wallsurrounding the first closed end, and a first open end opposite thefirst closed end. The second portion has a second closed end, at leastone second side wall surrounding said second closed end, and a secondopen end opposite the second closed end. The first portion and secondportion are movably connected at their respective open ends. The atleast one indicator is placed in communication with the package suchthat when the package is expanded to a desired inner volume theindicator is activated. The first or second portion that is a topportion of the food package has a closed end that can be opened with thepackage is expanded to a desired inner volume allowing access to theexpanded food product.

FIGS. 8 and 9 depict the pattern as producing a first and/or secondportion having a square/rectangular cross section. However, in otherembodiments of the pattern may produce a first and/or second portionhaving any cross sectional shape may be used, for example, a crosssection that is circular, square, rectangular, octagonal, triangular,hexagonal, pentagonal, or any combination thereof.

Another embodiment of the method of packaging further includes providinga package having interface portions, which prevent the package fromexpanding to far and separating the first and second portions apart.Providing a package with interface portions includes providing a firstportion with at least one first interface portion at the first open endof the first portion and a second portion with at least one secondinterface portion at the second open end of the second portion.

Another embodiment of the method of packaging includes the step ofsealing the food product in a bag 703. Sealing the food product in bag,within the package, prevents the food product from becoming contaminatedduring the storage, transportation, and manufacturing of the packagedfood product. Furthermore, the food product can be sealed in a plasticbag, a thermoplastic bag, a foil or metallic bag, a paper bag, a baghaving the desired barrier properties such as moisture or gas barrierproperties, any other contamination preventing covering, or anycombination thereof. Optionally, the step of sealing the food product ina bag 703 may further include sealing the food product in a bag having alarge enough volume to expand the packaging enough to activate anindicator, allowing the food product to expand within the bag and reachthe desired volume.

According to the invention, the patterns forming the food package aremade from standard virgin fiber paperboard that is food grade. It iscontemplated within the scope of the invention that the patterns may bemade from card stock, paperboard, polymers and combinations thereof. Itis further contemplated within the scope of the invention that layeredmaterials containing layers of paper and polymeric films may form thematerial that the patterns are made from.

While the invention has been described and illustrated in connectionwith preferred embodiments, many variations and modifications will beevident to those skilled in the art and may be made without departingfrom the spirit and scope of the invention. The invention is thus not tobe limited to the precise details of methodology or construction setforth above as such variations and modification are intended to beincluded within the scope of the invention.

What is claimed is:
 1. A package for food products comprising: a firstportion having a first closed end, at least one first side wallsurrounding said first closed end, and a first open end opposite saidfirst closed end; a second portion having a second closed end, at leastone second side wall surrounding said second closed end, and a secondopen end opposite said second closed end; said second open end of saidsecond portion being movably attached to said first open end of saidfirst portion; and at least one indicator in communication with saidpackage such that when said package is expanded to a desired innervolume said indicator is activated.
 2. The package of claim 1, furthercomprising at least one first interface portion at said first open endand at least one second interface portion at said second open end,wherein said first interface portion engages with said second interfaceportion.
 3. The package of claim 1, wherein said first closed end ofsaid first portion is openable.
 4. The package of claim 1, wherein saidindicator is activated when said inner volume of said package is in therange of about 108 to 112 cubic inches.
 5. The package of claim 1,wherein said indicator is activated when said inner volume of saidpackage is in the range of about 90 to 94 cubic inches.
 6. The packageof claim 1, wherein said second portion is smaller than said firstportion such that said second portion fits inside of said first portion.7. The package of claim 1, wherein said first portion is smaller thansaid second portion such that said first portion fits inside of saidsecond portion.
 8. A method of making a package comprising the steps of:providing a first portion pattern; providing a second portion pattern;folding said first portion pattern to form a first portion having afirst closed end, at least one first side wall surrounding said firstclosed end, a first open end opposite said first closed end, and atleast one first interface portion at said first open end; folding saidsecond portion pattern to form a second portion having a second closedend, at least one second side wall surrounding said second closed end, asecond open end opposite said second closed end, and at least one secondinterface portion at said second open end; fastening said first portionsuch that said first portion retains the folded configuration; fasteningsaid second portion such that said second portion retains the foldedconfiguration; and assembling said first portion and said second portionsuch that said first interface portion of said first portion engageswith said second interface portion of said second portion and said firstportion and said second portion are movably attached.
 9. The method ofclaim 8, further comprising the step of providing a sheet stock.
 10. Themethod of claim 9, further comprising the step of printing said sheetstock.
 11. The method of claim 8, further comprising the step of cuttinga first portion pattern.
 12. The method of claim 8, further comprisingthe step of cutting a second portion pattern.
 13. A method of packaginga food product comprising the steps of: providing a food product;providing a package comprising: a first portion having a first closedend, at least one first side wall surrounding said first closed end, anda first open end opposite said first closed end; a second portion havinga second closed end, at least one second side wall surrounding saidsecond closed end, and a second open end opposite said second closedend; said second open end of said second portion being movably attachedto said first open end of said first portion; and at least one indicatorin communication with said package such that when said package isexpanded to a desired inner volume said indicator is activated; andenclosing said food product within said package.
 14. The method of claim13, further comprising the step of sealing said food product in a bag.15. The method of claim 14, wherein said bag is a plastic bag.
 16. Themethod of claim 14, wherein said bag is a thermoplastic bag.
 17. Themethod of claim 13, wherein said step of providing said package furtherincludes providing a first portion having at least one first interfaceportion at said first open end and a second portion having at least onesecond interface portion at said second open end.
 18. The method ofclaim 14, wherein said bag is large enough such that said bag is capableexpanding said package to activate said indicator.